SECTION 5 TROUBLESHOOTING

Group 1 Before Troubleshooting --------------------------------------------------------------------------------- 5-1

Group 2 Hydraulic and Mechanical System -------------------------------------------------------------- 5-4
Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-24
GROUP 1 BEFORE TROUBLESHOOTING

1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system and Electrical system system.
At each system part, an operator can check the machine according to the troubleshooting process
diagram.

Hydraulic &
Mechanical part GROUP 2

Troubles occur

Electrical part GROUP 3

5-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.

STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the
related parts of the trouble.
13031SH02

STEP 2. Ask the operator

Before inspecting, get the full stor y of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which par ts were
13031SH03
repaired before.

STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
6-2(3) 140-7
the controllers causing total operational failures
of the machine.

5-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.

6-3(1) 140-7

STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.

13031SH05

STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what the
real cause of the trouble is.

Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.

6-3(3) 140-7

5-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
Η Was there any strange thing about machine before failure occurred?
Θ Under what conditions did the failure occur?
Ι Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
Η Check oil and fuel level.
Θ Check for any external leakage of oil from components.
Ι Check for loose or damage of wiring and connections.

5-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".

5-5
 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise
pump and pump YES comes out of YES
connections pump See item 1).
YES
make abnormal connection at page 5-5
noise?

Is primary pilot
pressure within ͽ
NO standard level?

YES
Clean pilot
Is not pilot piping
clogged or is not piping interior or
YES
oil leakage repair piping.
present on pilot
piping?
NO Pilot valve is Disassemble
ͽ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?

NO Gear pump is Disassemble

broken. and repair.

5-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY

Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.

Air is intruded. Check suction

NO
line and return
line and eliminate
the air intruding
source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil
level.
volume proper? YES
Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES
ͽ
air circulation?
Is fan belt
NO tension proper?
Adjust belt
NO
tension or
replace belt.
Is not the set YES
pressure of main Readjust set
relief, relief and pressure.
ͽ
travel relief valve Is main relief
lower than the YES
valve used very Reduce load.
standard level? NO often?

5-7
 3) CAVITATION OCCURS WITH PUMP

Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO
suction line? intrusion in
suction line and
retighten or
replace parts.

4) HYDRAULIC OIL IS CONTAMINATED

Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.

5-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

Cause Remedy
NO
Replenish
YES ͽ specified oil to the
YES
Is safety solenoid
valve pressure standard level.
Is gear pump pilot within standard? Safety valve faulty Repair or replace.
NO
pressure within or not operated.
YES standard level?
Is oil in hydraulic
YES tank within
Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble
of coupling present coupling is broken. and repair.
ͽ when dust plug
under engine fly Is not main relief NO Hydraulic pump is
Are attachment wheel is removed? NO valve faulty? Disassemble
and travel out of order. and repair.
motions
impossible at all? NO Swing control
Does swing Disassemble
YES control valve valve spool is and repair.
spool move
Is MCV pilot lightly by hand? ; stuck.
YES YES
pressure within
standard level?
Does dozer Ϳ
NO
NO function?

Hydraulic pump is Disassemble

NO
broken. and repair.

YES
Swing brake Disassemble
release valve is and repair.
Is swing brake broken.
; release valve
faulty? YES Swing reduction Disassemble
Does swing unit is broken. and repair.
NO motor rotate?
Swing motor is Disassemble
NO
broken. and repair.

YES Pilot relief valve is Disassemble

NO Is gear pump faulty. and repair or
delivering oil? replace.

Is gear pump pilot Gear pump is out Disassemble

NO
Ϳ pressure within of order. and repair.
standard level?
YES Clean pilot piping
Is not there oil interior or repair
leakage from
piping.
YES pilot piping or is
not it clogged? Pilot valve is Disassemble
NO
broken. and repair.

5-9
 2) SWING SPEED IS LOW

Cause Remedy
Does swing YES
Swing port relief Disassemble and
control valve valve is faulty. repair or replace.
YES
spool move
smoothly by
hand? Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
Is not pilot piping
Single direction clogged or is not piping.
NO it leaking oil?
Is the trouble in Pilot valve or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES ͽ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within NO
Is dozer speed spool is stuck. and repair.
standard level?
within standard ;
value? NO
Ϳ
NO

Is swing motor's NO
ͽ drain rate within Swing motor is Disassemble
standard value? Check that pilot broken. and repair.
piping is not
YES clogged or oil is NO
Pilot valve or Disassemble
not leaking from shuttle valve is and repair.
it?
faulty.
Clogged or oil Clean pilot piping
Is gear pump pilot leak. interior or repair
; pressure within piping.
standard level?
YES
Pilot relief valve Disassemble and
Is gear pump is defective. repair or replace.
NO delivering oil?
Gear pump is Disassemble
NO
broken. and repair.

NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the
YES
Ϳ valve setting symptom Hydraulic pump Disassemble
pressure normal? YES change when LH is broken. and repair.
and RH pilot
hoses are Shuttle valve is Repair or replace.
Is safety valve exchanged? NO
pilot pressure faulty.
YES within standard
level? YES
Is gear pump Pilot relief valve Repair or replace.
output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
NO
faulty.

5-10
 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

Cause Remedy
Does symptom YES
Swing port relief Disassemble
change when LH
YES and RH port valve is faulty. and repair.
relief valves are
exchanged Shuttle valve is Disassemble
Does swing control NO
YES faulty. and repair.
valve spool move
smoothly by hand?

Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
Check if pilot YES
Pilot valve is faulty. Disassemble
piping is not and repair.
clogged or does
NO
not have oil Clogged or oil
leakage. leak. Clean pilot piping
interior or repair
piping.

4) MACHINE SWINGS BUT DOES NOT STOP

Cause Remedy
YES Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
Gear pump is
NO
broken. Disassemble
YES Does swing control
valve spool move and repair.
smoothly by hand? Pilot valve is faulty.
NO
Disassemble
Is swing control and repair.
valve's return
spring normal? Swing control
NO
valve spool is Disassemble
stuck. and repair.
Return spring is
NO
faulty. Disassemble
and replace.

5-11
 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

Cause Remedy
YES
ͽ
YES Is swing shuttle

Shuttle valve is Disassemble

NO
faulty. and replace.
YES Is brake spring
normal?

Is return spring
of swing control Brake spring is Disassemble
NO
valve normal? faulty. and replace.

NO Return spring of Disassemble

swing control and replace.
valve is faulty.
YES
Is drain rate of Swing relief valve Disassemble
YES swing motor is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
ͽ NO
pressure within broken. and repair.
standard level?

NO Adjust swing
relief valve
pressure or
replace swing
relief valve.

5-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES
Does counterbalance ͽ
YES spool in travel
brake valve move
lightly by hand? Counter spool in Disassemble
Is travel brake NO
YES valve pressure travel brake valve and repair or
within standard is stuck. replace.
Does the symptom
change when
relief valves in YES Relief valve built
Disassemble
Has travel NO travel motor are
in travel motor is and repair.
YES control valve exchanged?
spool changed faulty.
over positively?
YES Control system is Disassemble
defective. inspect and
Does spool move repair.
NO lightly by hand?

NO
Travel control Disassemble
valve spool is and repair.
stuck.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ͽ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the
NO
symptom change YES
when P1 and P2 Hydraulic pump is Disassemble
Does the pump discharge
symptom change broken. and repair.
hoses are
when LH/RH
NO
travel relief valves
are exchanged?
YES
Travel relief Disassemble
valves are faulty. and repair or
replace.

5-13
 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES

Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
and RH travel YES
Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
Has control valve travel motors are
YES
spool changed exchanged? ͽ
over positively? NO
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is
Is the lower repair.
NO cut off from
speed(Bucket or
arm) within Control valve Disassemble
NO
spool is stuck. and repair.

YES
Travel relief valve Disassemble
Do LH and RH
travel speeds is faulty. and repair or
change over when replace.
NO travel relief valves
are exchanged?
Hydraulic pump is Disassemble
NO
broken. and repair.
Does travel speed
change when
YES parking brake YES
Travel motor's Disassemble
spring in the
slower travel parking brake is and clean pilot
Is leak rate of motor is removed? not released piping.
ͽ travel motor within
standard level? properly.

Travel motor is Disassemble

NO
faulty. and repair.

5-14
 3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.

Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
not clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?

Brake valve is Disassemble

NO
faulty. and repair or
replace.

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
Is bucket or arm disabled is
operation extremelyseldom
possible? statistically.
OK
Hydraulic pump is Disassemble
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty
is faulty. and repair or
no coupling
element particles. replace.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank.
broken. and repair.

Short Replenish
hydraulic oil.

5-15
 5) TRAVEL ACTION IS POWERLESS (travel only)

Cause Remedy
YES
ͽ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES pressure within NO
faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard is defective. and repair or
level?
replace.
NO
Travel relief valve Disassemble
is faulty. and repair or
replace.

YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in with dirt.
travel motor,
draw out piston Parking brake Disassemble
ͽ NO
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.

6) MACHINE RUNS RECKLESSLY ON A SLOPE

Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.

5-16
 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME

Cause Remedy
YES
Normal.

YES Is select valve

normal?

Select valve is Repair or

Is travel lever NO
faulty. replace.
operate
normal? YES
Remove dirt on
Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief NO
NO
control valve not Pilot relief valve is Disassemble
valve normal?
clogged? defective. and repair or
Is gear pump
replace.
NO delivering oil?

Gear pump is Disassemble

NO
broken. and repair.

5-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ͽ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
NO
Are other not leaking from
YES faulty. and repair.
attachments the piping.
operatable?

Pilot relief valve is Disassemble

Is gear pump YES Is gear pump faulty. and repair or
pilot pressure
NO delivering oil? replace.
within standard
NO
Gear pump is Disassemble
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.

YES
Cylinder interior is Disassemble
Does control
ͽ broken. and repair.
valve spool move
lightly by hand?
NO Control valve Disassemble
spool is stuck. and repair.

5-18
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ͽ
YES attachment
Is combination speeds within
Is speed low only ;
of oil streams NO
in composite YES
normal at boom YES
operation? hoisting and at Flow summation Disassemble
Does spool of
arm extrusion? flow summation check valve spool and repair.
NO check valve is stuck.
Are LH/RH travel
move lightly by
NO speeds within NO
standard levels?
YES
Hydraulic pump is Disassemble
Are both LH/RH faulty. and repair.
travel speeds YES Ϳ
NO
low? Is MCV pilot
pressure within
NO
standard? ΀
NO
OK
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES NO
valve spool move and repair.
lightly by hand?

NO Control valve spool Disassemble

Is MCV pilot
ͽ pressure within is stuck. and repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil Pilot valve is Disassemble
NO
defective. and repair.
YES
Pilot relief valve is Disassemble
Is primary pilot NO Is gear pump faulty. and repair or
; pressure within
delivering oil? replace.
standard level?
NO
Gear pump is Disassemble
broken. and repair.
Is engine NO
Ϳ revolution within Adjust engine
standard level? revolution.

YES
Clean orifice in
control valve.
Is not orifice in
΀ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? Is pilot valve
Pilot valve is faulty. Disassemble
NO normal? NO
and repair.

5-19
 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND
ATTACHMENT FALLS

Cause Remedy
YES
Port relief valve is Disassemble
Does the faulty. and repair or
symptom change
Normal replace.
when port relief YES
valve is replaced ͽ
with normal Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
temperature rise
used?
and lower it to
proper level.

Replace with
NO
genuine
hydraulic oil or
equivalent.

OK
Pressure Disassemble
Disassemble and tightness and repair.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder Abnormal Contact surface Disassemble
ͽ internal leakage between poppet and repair.
within standard
and seat is poor.

Cylinder is faulty. Disassemble

NO
and repair.

5-20
 4) BOOM, ARM OR BUCKET POWER IS WEAK

Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
faulty. repair or replace.

Main relief valve Adjust pressure,

NO
is defective. repair or replace.

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Cause Remedy
YES
Port relief valve is Disassemble
Does the
symptom change defective. and repair or
YES
when port relief replace.
YES
valve is replaced Does control Cylinder interior is Disassemble
valve spool broken. and repair.
Is MCV pilot NO move smoothly
pressure within
standard level? NO Control valve Disassemble
spool is stuck. and repair.

NO Pilot valve is Disassemble

faulty. and repair.

5-21
 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
ö Frictional
noise will
disappear if
they are kept
used.

Boom foot pin Supply grease

NO
has run out of to it.
grease. ö If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.

5-22
ö HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

R5575BY01

2. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends)

R5575BY02

3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
R5575BY03

5-23
 GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.2 and No.5.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-56 poor contact (after clean)
(2) and chassis between CN-56
Starting switch : ON
(1) and fuse No.5.
Voltage : 10~12.5V
Disconnection in Repair or
NO
wiring harness or replace
poor contact (after clean)
between CN-56
(2) and fuse No.2

Check voltage
YES 10 ~ 12.5V
NO 0V

CLUSTER FUSE
POWER IG(12V) 1
POWER 12V 2 NO.5

FUSE

NO.2
CN-56

5595TS01

5-24
2. BATTERY CHARGING WARNING LAMP LIGHTS UP (starting switch : ON)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-57
(3) and chassis Disconnection in Repair or replace
NO
wiring harness or (after clean)
YES Check voltage poor contact
between CN-1
(3) and chassis between CN-57(3)
-CN1(3)
Check voltage Disconnection in Repair or replace
between NO wiring harness or (after clean)
alternator poor contact
terminal "L" and between
chassis CN-1(3)-alternator
terminal "L"
Voltage : 10~12.5V
Engine : Running

NO
Defective alternator Replace

Check voltage
YES 10 ~ 12.5V
NO 0V

ALTERNATOR
CLUSTER B+ G
2 s 3 ~
3 3 1 L
U
P
CN-74
CN-57 CN-1

5595TS02

5-25
3. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-30 (110˚C Ü2˚C ) cooling system
(1,2) is in range
of 120~150̫?
NO
Defective temp Replace
Does display go Disconnect CD-30 sensor
off when
disconnect
CD-30? YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (after clean)
between CN-56
NO
(17,19) is 0~1̫?
Defective cluster Replace
Disconnect CN-56 NO
KEY OFF

CLUSTER

WATER TEMPERATURE SENSOR

17 7 1 C

19 8 2
CD-30
CN-1
CN-56

5595TS03

5-26
4. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect
CD-10? YES
Short circuit in Repair or replace
Starting switch : ON
Engine : Start Check resistance wiring harness (after clean)
between CN-57
NO
(3) and chassis
Starting switch : OFF Defective cluster Replace
NO
Disconnect CN-57

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER
AIR CLEANER SWITCH
AIR CLEANER SWITCH

Pa
3 11
CN-57 CN-1 CD-10

555C95TS13

5-27
5. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective cluster Replace
Starting switch : ON Check resistance
Engine : Start between CN-57
NO
(2) and chassis
Starting switch : OFF
Disconnection in Repair or replace
NO
Disconnect CN-57 wiring harness or (after clean)
poor contact
between
CN-57 (2)-CD-18

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER ENGINE OIL

ENGINE OIL PRESSURE
PRESSURESWITCH
SWITCH

2 2 Pa

CN-57 CN-1 CD-18

555C95TS14

5-28
6. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100˚C Ü2˚C ) ,
of 130~150̫? Replace
Does display go Starting switch : ON Defective temp Replace
NO
off when Disconnect CD-1 sensor
disconnect
CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-56
NO (16) and CN-57
(11) is 0~1̫?
Starting switch : OFF NO Defective cluster Replace
Disconnect CN-56,
CN-57

CLUSTER
CLUSTER
CN-56
HYDRAULIC OIL
TEMPERATURE SENDER

16 9 2
C

11 8 1

CN-1 CD-1
CN-57

555C95TS15

5-29
7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (after clean)
Is resistance poor contact
YES between CN-56
between
(17) and CN-56 CN-56-CD-30
(11) over 2k̫?
Starting switch : OFF YES
Disconnect CN-50 Defective cluster Replace
Does the gauge
move up and Check resistance
down at lamp NO
between CN-1
check? (8) and (7)
Defective temp Replace
See Table NO
Starting switch : ON sensor

Defective cluster Replace

NO

Red range Check Table

Temperature 115˚C
40˚C 85~110˚C
Item (red range)

Unit Resistance(̫) 1170~ 270~130 ~124

Tolerance(%) Ü5 8~0 Ü5

CLUSTER

WATER TEMPERATURE SENSOR

17 7 1 C

19 8 2
CD-30
CN-1
CN-56

5595TS03

5-30
8. WHEN FUEL GAUGE DOES NOT OPERATE (check warning lamp ON/OFF)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-56
(15) and CN-57
(11) over 1k̫? YES
Defective cluster Replace
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2
move up and NO (1) and (2)
down at lamp Defective fuel Replace
Disconnect CD-2 NO
check? sensor
See Table
Starting switch : ON

Defective cluster Replace

NO

Red range Check Table

Level Empty 1/2 Full
Item
Unit Resistance (̫) 700 300 ~100
Tolerance (%) Ü5 Ü8 Ü5

CLUSTER
CN-56
FUEL SENDER

15 6 2

11 13 1

CN-1 CD-2
CN-57

555C95TS16

5-31
9. WHEN SAFETY SOLENOID DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.14.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Defective switch Repair or replace
YES Check voltage (CS-4)
between CS-4
Check voltage (3) and chassis
between CN-68 Disconnect in Repair or replace
Check voltage Starting switch : ON NO
(1) - CN-68 (2) YES between CN-5 Voltage : 10~12.5V wiring harness or (after clean)
Starting switch : ON (10) and chassis
Disconnect CN-5 poor contact
Voltage : 10~12.5V between
Safety state Starting switch : ON CN-5 (10)-CS-4 (3)
Voltage : 10~12.5V
Disconnect CN-5
Check voltage Disconnect in Repair or replace
between CN-68 NO
wiring harness or (after clean)
NO (2) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-5 (10)-CN-68 (2)
Voltage : 10~12.5V

NO Disconnection in Replace
fuse

FUSE

NO.17

SAFETY SWITCH
2 3 1 SAFETY SOLENOID
2 1
1 3 10 2
CS-4 CN-68
CN-5

555C95TS17

5-32
10. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.15.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-56 YES
of solenoid Defective cluster Replace
Check if travel (8) and chassis
speed lamps( Check resistance
Starting switch : ON Starting switch : ON between CN-70
, ) change Voltage : 10~12.5V : OFF NO
when pressing the Disconnect CN-56 : ON
(1) and (2)
travel speed Starting switch : OFF NO Defective solenoid Replace
switch on the SPEC : 15~25̫
cluster Disconnect CN-70
Starting switch : ON Defective cluster Replace
NO

CLUSTER

8
TRAVEL SOLENOID

CN-56 9 2
1
CR-12 CN-4 CN-70
87a
86 30
85
87 FUSE
86
85 87 87a
30 NO.15
TRAVEL HI-LO SOL

555C95TS18

5-33
11. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.13 is not blown out.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Recheck fuse Replace

Check voltage
NO
between CS-3 Defective wiper Replace
(11) and chassis switch

Voltage : 10~12.5V Check voltage

between CS-3
YES
(7) and chassis YES
Defective Int wiper Replace
Wiper switch : ON Check voltage relay, wiper relay,
Voltage : 10~12.5V between CR-6
wiper motor
YES (4),CR-4 (86),CN-
21 (3) and chassis
Recheck fuse Replace
Starting switch : ON NO
Voltage : 10~12.5V

WIPER SW WIPER RY WIPER MOTOR WASHER SW

INT.WIPER RY 12
12
12

10
6

4
9
85

86
87a 87

30

DO-1
CS-30
I 0
11
11

CR-6

8
CR-4
CS-3

CN-21
9
4

3
7
5 10

4 Lo

2 E
1 Pf
3 B
87a

10
11
12
30
86

85
10

87
1
4
6

9
4

8
A
B

1
2
3

6
7
3

7
2

6
1

8
9

2
1
1
2
3
4

CN-22
M 2

CN-5 1
WASHER P/P
FUSE 3
11
NO.13
555C95TS21

5-34
12. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.10.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective light Replace switch
switch

Check voltage
YES between CN-116
YES
(1) and CR-13 Defective bulb Replace
Check voltage
(30) YES between CL-3
Starting switch : ON (2)/ CL-4 (2) and
Head lamp switch : ON chassis
Voltage : 10~12.5V Disconnection in Repair or replace
Starting switch : ON NO
Check voltage wiring harness or (after clean)
Head lamp switch : ON
between CR-13 Voltage : 10~12.5V poor contact
YES (87) and CN-4 between CN-4 (2)
(2) chassis
Check voltage -CL-3 (2)/CL-4 (2)
Starting switch : ON
between CN-116 Head lamp switch : ON
(1) and chassis Voltage : 10~12.5V
Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (after clean)
Head lamp switch :
ON-OFF poor contact
between
CR-13 (87)-CN-4 (2)

Disconnection in Repair or replace

NO
wiring harness or (after clean)
poor contact
between CN-116
(1) and fuse
SWITCH PANEL
NC 12
GND 11
POWER 12V(IG) 10
BREAKER 9 CN-4 HEAD LAMP
TRAVEL ALARM 8 1
CABIN LIGHT OUT 7 2 2
SEAT HEAT 6 CL-3
NC 5
NC 4 1
NC 3
CR-13 2
WORK LIGHT OUT 2 87a 30 86
HEAD LIGHT OUT 1 85 CL-4
CN-116 87
86
87a 87 85
30

CN-245 FUSE
9

NO.10
REMOTE 555C95TS22

5-35
13. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.11.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective light Replace switch
switch

YES
YES Check voltage Defective bulb Replace
between CN-116 YES Check voltage
(2) and CR-3 (86) between CL-5
(2) and chassis
Starting switch : ON Disconnection in Repair or replace
Work lamp switch : ON Starting switch : ON NO
Voltage : 10~12.5V Work lamp switch : ON
wiring harness or (after clean)
Check voltage Voltage : 10~12.5V poor contact
between CN-4
YES (8) and CR-3(87) between CN-4 (8)
and CL-5 (2)
Starting switch : ON
Check voltage Work lamp switch : ON
between CN-116 Voltage : 10~12.5V
(2) and chassis Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (after clean)
Work lamp switch :
ON-OFF poor contact
Voltage : 10~12.5V between
CN-116 (2)-CN-4
(8)

Disconnection in Repair or replace

NO
wiring harness or (after clean)
poor contact
between CN-116
(2) and fuse
SWITCH PANEL
NC 12
GND 11
WORK LAMP
POWER 12V(IG) 10 CN-4 CN-12
1
BREAKER 9
TRAVEL ALARM 8 8 2 2
CABIN LIGHT OUT 7 CL-5
SEAT HEAT 6
NC 5
NC 4
CR-3
NC 3 87a 30 86
WORK LIGHT OUT 2 85
HEAD LIGHT OUT 1 87
CN-116 86
87a 87 85
30

FUSE

NO.11 555C95TS23

5-36
14. WHEN ENGINE DOES NOT START CIRCUIT BREAKER
MANUL RESET

ÂCheck supply of the power at engine stop solenoid while starting switch is ON. 50A

ÂBefore disconnecting the connector, always turn the starting switch OFF.

CN-60
CN-95
NO.14

1
FUSE

1
2
NO.2
ÂBefore carrying out below procedure, check all the related connectors are properly inserted. CR-1
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. 1
2

CN-3 BATT RY
1
2
Cause Remedy BATTERY
MASTER SW CN-5
YES
Defective battery Check engine
1
system charge 2 9
or replace (after CS-74
checking specific
gravity of battery)
Check operation YES START SWITCH FUEL CUT-OFF SOL DO-3
Check voltage Defective magnet Replace
of start motor YES between starter of start motor
H A
1
2

FUSE F B

II I O H
magnet coil and 1

I,O
E C
Starting switch : START NO.1
chassis Defective start relay Replace 2 CN-79
NO FUSE
3 4

H
Starting switch : START YES NO.5
SPEC : 10~12.5V ͽ 4

ACC BR
1

B
FUEL CUT-OFF RY
Check operation Check voltage 2
3
YES 5 C1 1 C1
between CR-5
NO of start relay 6 C2
(30) and chassis 1

C ST
Disconnection in Repair or replace 5
2
Starting switch : START
NO 6 C2 2

Starting switch :START wiring harness or (after clean) FUSE CS-2

CR-47
Check operation poor contact
of start safety NO.8
NO relay between CR-5
(87) and CN-4(11) CN-4
STARTER MOTOR
YES 1
Starting switch : ON Defective relay Replace TIMER B+
M
Check voltage IG 4 OUT
1 3
1
between CR-5 2 4
M
NO 2 3
(87) and chassis ⓑ GND 3 OUT 4 CN-45
NO CR-50 START RY
1 C1
FUSE
11 C2
C1
YES
Defective relay Replace NO.16
1
Check voltage CN-1 2 2 C2

ͽ between CR-23 CR-5 CR-23

87a 1
and chassis Disconnection in Repair or replace
86 30
85 DO-2 RS-2
87 3
NO wiring harness or (after clean) 86
1 2

Starting switch : ON 85 87 87a

30
4 2 1

poor contact RESISTER

ANTI-RESTART RY
between CR-5 CLUSTER CN-74
(87)-CR-23 (2) 3 ALT LEVEL
B+ G
2 s
L
3 ~
1
5 TACHO SIGNAL U
YES P
Defective fuel cut- Replace 6 ALTERNATOR

ACCEL DIAL
ANTI-RESTART RY
Check voltage off solenoid
;

CN-142
between CR-79

S
+
CN-56

-
and chassis Disconnection in Repair or replace

C
A
B
NO wiring harness or (after clean)
Starting switch : ON
SPEC : 10~12.5V between CN-79-
CR-23(2) CN-7

16
13
14
15
CN-51

CN-76
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
2
3
4
5
6
7
8
9

6
5
4
3
2
1
A_IN BOOM SWING PS
D_OUT GOV. MOTOR+

D_OUT GOV. MOTOR-

12V POWER SUPPLY

SIG
D_OUT TRAVEL BZ

NC
A_IN WORKING PS

M+

P+

P-
PROGRAM_DUMP

M-
A_IN TACHO_SIG
D_IN TRAVEL PS

D_OUT SPARE3
D_OUT SPARE2
D_OUT SPARE1

POWER IG_12V

1
5
A_IN DIAL_SIG
A_IN POT_SIG

2
POT_DIAL_5V

D_IN SPARE3
D_IN SPARE1
D_IN SPARE2

M
A_IN SPARE3

A_IN SPARE4

A_IN SPARE1

A_IN SPARE2
RCV EPPR+

RS232_RX2
RS232_RX1

RS232_TX2
RS232_TX1

RCV EPPR-

GND_MAIN
GND_MAIN
ALT LEVEL
RS485_RX

CAN_GND
RS485_TX

BATT. 12V

BATT. 12V

3
SIG. GND
CAN_Lo
CAN_Hi
GOVERNOR MOTOR

Govenor DC MOTOR Controller

555C95TS20

5-37
15. WHEN STARTING SWITCH ON DOES NOT OPERATE CIRCUIT BREAKER
MANUL RESET

ÂBefore disconnecting the connector, always turn the starting switch OFF. 50A

ÂBefore carrying out below procedure, check all the related connectors are properly inserted and

CN-60
CN-95
NO.14

1
FUSE

1
2
NO.2
master switch ON. CR-1
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. 1
2

CN-3 BATT RY
1

Cause Remedy 2
MASTER SW BATTERY
YES CN-5
Disconnection in Repair or
1
wiring harness or replace 2 9
poor contact (after clean) CS-74

between CN-5
YES Check voltage
between CR-1 (9)-CR-1 (2) or START SWITCH FUEL CUT-OFF SOL DO-3
(2) and chassis defective battery H A 2
1
FUSE F B
Voltage : 10~12.5V relay

II I O H
1

I,O
E C
NO.1
2 CN-79
FUSE
4
Disconnection in Replace 3

H
YES
Check voltage NO NO.5
4

ACC BR
1

B
between CS-2 wiring harness or 2 FUEL CUT-OFF RY
3 C1 1 C1
(2) and chassis 5
poor contact 6 C2
1
between CS-2

C ST
Voltage : 10~12.5V 5
C2 2 2
6
CS-2
(2)-CN-5 (9) FUSE
YES Check voltage
CR-47
between CS-2(1) NO.8
and chassis Defective start Replace CN-4
NO STARTER MOTOR
Voltage : 10~12.5V switch TIMER 1 B+
IG 4 OUT
1 3
M
1
2 4
Check voltage NO
Disconnection in Replace 2 3 M
and specific wiring harness or GND 3 OUT 4 CN-45
CR-50 START RY
gravity of battery poor contact 1 C1
FUSE
11 C2
C1
Specific gravity : MIN 1.28 between CS-2 1
Voltage : MIN 12V NO.16
(1)-fuse No.1 CN-1 2 2 C2

CR-5 CR-23
86 30
87a 1
85 DO-2 RS-2
Battery capacity Charge or 87 3 1 2
NO 86
4 2 1
too low replace 85 87 87a
30
RESISTER
(after clean) ANTI-RESTART RY
CLUSTER CN-74
B+ G
3 ALT LEVEL 2 s 3 ~
1 L
5 TACHO SIGNAL P
U

6 ALTERNATOR

ACCEL DIAL
ANTI-RESTART RY

CN-142

S
+
CN-56

-
C
A
B
CN-7

16
13
14
15
CN-51

CN-76
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
2
3
4
5
6
7
8
9

6
5
4
3
2
1
A_IN BOOM SWING PS
D_OUT GOV. MOTOR+

D_OUT GOV. MOTOR-

12V POWER SUPPLY

SIG
D_OUT TRAVEL BZ

NC
A_IN WORKING PS

M+

P+

P-
PROGRAM_DUMP

M-
A_IN TACHO_SIG
D_IN TRAVEL PS

D_OUT SPARE3
D_OUT SPARE2
D_OUT SPARE1

POWER IG_12V

1
5
A_IN DIAL_SIG
A_IN POT_SIG

2
POT_DIAL_5V

D_IN SPARE3
D_IN SPARE1
D_IN SPARE2

M
A_IN SPARE3

A_IN SPARE4

A_IN SPARE1

A_IN SPARE2
RCV EPPR+

RS232_RX2
RS232_RX1

RS232_TX2
RS232_TX1

RCV EPPR-

GND_MAIN
GND_MAIN
ALT LEVEL
RS485_RX

CAN_GND
RS485_TX

BATT. 12V

BATT. 12V

3
SIG. GND
CAN_Lo
CAN_Hi
GOVERNOR MOTOR

Govenor DC MOTOR Controller

555C95TS20

5-38